Assembly and Disassembly of Take-up Roller

Caution ・ To ensure safe operations, wear protective devices before beginning work and follow all precautions. ・ When removing devices or positioning devices at the time of installation, use a removal jig and a hammer or steel rod. ・ Follow the precautions below when suspending the load. ・ The crane must be operated by a qualified operator. ・ Do not stand or pass under the suspended load. ・ Check the weight of the roller to determine whether it can be carried by hand or whether a crane must be used. ・ Fix the roller to a level surface so it does not roll. ・ Be sure to repair any parts damaged during disassembly, and prepare replacement parts in advance. ・ If any parts are significantly rusted or dirty, clean them before disassembling. ・ Any foreign matter entering the equipment during assembly can create a malfunction. Therefore, after thoroughly cleaning the equipment with cleaning oil, air blow the equipment, and assemble in a clean location. ・ When assembling sliding (5) parts, be sure to coat them with new hydraulic oil. ・ As a rule, replace all O-rings and other seal parts with new parts. ・ The take-up roller is a heavy object and requires at least 2 workers to handle. <General cautions> ・ Be careful not to drop precision parts or let bump them with other parts during work. ・ Do not forcefully open or hit parts in an effort to speed up operations. Pay careful attention and proceed with caution so as not to damage any parts, create any oil leaks, or compromise the efficiency of the equipment. ・ Disassembled parts can easily rust or collect dust. Therefore, immediately after disassembling parts, take precautions to prevent the parts from rusting or collecting dust.

Items to prepare •Hexagon wrench (6 mm) •Hammer •Wire clips •Pliers •Gear puller •Screwdriver •Engine oil (Shell Rimula Oil #30) •Specialty jigs •Pressing machine •Loctite •Special fiber cloth (Kimwipe) •Micrometer caliper •Caliper •Cylinder gauge •Seal tape •Oil pan (drip pan) •Water container for inspection

Configuration diagram

6

8

4

3

2

1

2

3

5

7

Dimension diagram

5

9

6

284 202 Part name Part number Q'ty 1 Roller KRA1768 1 2 Bushing KRA1201 2 3 Floating seal BLA2371 2 4 Hub KRA1200 1 5 O-ring 1A-G50 BHA0863 2 6 Wire clip KNA0180 2 7 Shaft KRA0988 1 8 Plug with seal nylon KHJ0300 1 9 Hub (without plug) KRA1594 1

Jig dimension diagram

20 5 50

40

10

7

1 9 2 3 5 4 6

30 X

C0.5 C0.5 0.5

15

C3

A Bushing removal jig B Bushing press-fit jig C Floating seal installation jig

Disassembly procedure [1] Stand the roller vertically and use a hexagon wrench (1) (6 mm) to remove the plug (2). •The plug is coated with seal nylon, which comes off when the plug is removed. To reuse the plug, use seal tape.

[2] Face down the part of the roller from which the plug was removed and empty the oil from within the roller. •It may take a few hours to completely empty the roller of oil. •Place an oil pan (3) under the roller to catch the oil.

[3] Remove the wire clip (4). Tap with the hammer (6) and use another wire (5) to push out from the outside the wire clip that is in the roller. •Securely fasten the roller before doing this work. •The wire in the roller is very securely fixed, so prepare several wire clips. Also be sure to coat with lubricant.

1 Hexagon wrench 2 Plug 3 Oil pan 4 Wire clip 5 Wire 6 Hammer

[4] Use pliers (7) to remove the pushed out wire clip (4).

[5] Use a gear puller (8) to remove the hub (9). •If the hub has rusted or is difficult to remove due to an accumulation of debris, subject it to a shock, for example by hitting it with a hammer, to make it easier to move. •When hitting the hub with a hammer, be careful not to dent it.

[6] Check whether the surface of the floating seal (10) sliding against the removed hub has rusted or is damaged. Also check whether the O-ring (11) is twisted. •The O-ring cannot be reused. Always replace it with a new one.

4 Wire clip 7 Pliers 8 Gear puller 9 Hub 10 Floating seal 11 O-ring 12 Ring

[7] Remove the floating seal (10) on the roller.

As described in Step [6] above, check whether the surface of the floating seal sliding against the roller shaft has rusted or is damaged. Also check whether the O-ring is twisted.

[8] Remove the O-ring (13) on the roller shaft (14). •The O-ring cannot be reused. Always replace it with a new one.

[9] Remove the shaft (14). [10]As described in Steps [3] - [6], remove the hub (15) on the opposite side and check that floating seal sliding surface is not rusted and that the O-ring is not twisted.

10 Floating seal 13 O-ring 14 Shaft 15 Hub

[11]As described in Step [7], remove the floating seal (16) on the opposite side.

[12]Use a micrometer caliper to measure the roller (with bushing) (18), hubs (15) and (17), and shaft (14) for wear and deformation. Replace with new parts as necessary.

14 Shaft 15 Hub 16 Floating seal 17 Hub 18 Roller 19 Micrometer caliper 20 Cylinder gauge 21 Caliper

[13]When replacing the bushing (23), remove it by placing a striking rod (22) against the end surface and striking that with a hammer (6) uniformly left and right as in the diagram.

[14]Invert the roller (18), use jig A (24) to push up against the bushing (23), and press with a rod-shaped object (14) (such as a shaft).

The bushing comes off.

6 Hammer 14 Shaft 18 Roller 22 Striking rod 23 Bushing 24 Jig A

Assembly procedure [1] Clean all parts. •Find a clean location. •Place a rubber plate or cloth on the work surface so as not to damage the parts.

[2] After cleaning the parts, air blow them to remove any remaining cleaning fluid or debris.

[3] If the bushing (3) was removed during disassembly, put it into the roller (2). Use a pressing machine (4) to press in both the left and right sides.

1 Cleaning fluid 2 Roller 3 Bushing 4 Pressing machine

[4] Use the jigs (5) and (6) attached to the pressing machine to attach the bushing (3).

Use the pressing machine to press from the opposite side. Next, use a special fiber cloth to remove all dust and debris.

[5] Attach the floating seal (8) to the hub (7).

Use jig C (9) to press the floating seal into position.

[6] Use jig C (9) to attach the floating seal (8) to the roller (2) side.

2 Roller 3 Bushing 5 Jig 6 Jig 7 Hub 8 Floating seal 9 Jig C

[7] Use a special fiber cloth to thoroughly wipe the sliding surface of the floating seal to prevent any dust or scratches.

[8] Apply engine oil to the floating seals (8) on the hubs.

[9] Attach O-rings (12) to the shaft (11) and mount them on the roller side.

7 Hub 8 Floating seal 10 Hub 11 Shaft 12 O-ring

[10]Install the hubs (7) and (10) on both sides.

[11]Attach the wire clip (13) to the hub.

[12]Inject compressed air (0.2 MPa) from the oil fill port and immerse in water to check that there are no leaks.

7 Hub 10 Hub 13 Wire clip

[13]Insert a wire clip and fill the engine oil (120 cc) into the roller main unit. •The roller main unit can be very unstable, so give consideration to securing it.

[14]After filling the oil, use a hexagon wrench (6 mm) (14) to tighten the plug (15) with the nylon seal applied. •To reuse a plug, wrap it with seal tape.

14 Hexagon wrench 15 Plug